Modular knock-down cabinet



June 2, 1970 JQF. HICKEY 3,515,451

MODULAR KNOCK-DOWN CABINET Filed June 11, 1968 2 Sheets-Sheet 1 p 4| 32" F162 v INVENTOR JOHN F HICKEY ATTORN EY 3,515,451 MODULAR KNOCK-DOWN CABINET John F. Hickey, 1104 Beechwood Drive, Hagerstown, Md. 21740 Filed June 11, 1968, Ser. No. 736,059 Int. Cl. A47b 47/00 US. Cl. 312-263 9 Claims ABSTRACT OF THE DISCLOSURE A knocked-down cabinet or the like for kitchens and bathrooms adapted to be readily assembled or built-up and attached to a wall by an inexperienced or unskilled individual. The front and end panels may be readily replaced without major disassembly of the cabinet, and the interior is free of corner posts or other protrusions when the cabinet is assembled.

This invention relates to cabinets such as utilized in kitchens and bathrooms or the like, and more particularly to a knocked-down type of modular cabinet.

Modular cabinets for kitchens or the like are well known and in extensive use. At the present time, however, such cabinets are usually sold in a preconstructed condition and are relatively bulky, heavy and diflicult to install by one person except by an expert. While various types of knocked-down cabinets which can be assembled on the job have been proposed, both to facilitate shipment and storage and to cater to the do-it-yourself market, such cabinets have not become popular since they are oftentimes complicated and difficult to assemble, the savings over prebuilt cabinets, if any, are too small, and the costs are out of the popular price range.

A primary object of the present invention, therefore, is to provide a new and improved knocked-down cabinet structure which is inexpensive, easily transported, and readily assembled and installed by a relatively inexperienced and unskilled individual.

A further object is to provide a modular cabinet structure which may be readily and simply assembled or builtup by one person on a wall or the like.

A further object is the provision of a modular cabinet structure in which the exposed front panel and the end or side panels, if exposed, may be readily replaced without disassembly of the entire cabinet, either to replace a damaged panel or to provide a new decor or styling change for the cabinet.

Another object is to provide a modular cabinet structure in which there are no glue joints so that several components may be replaced or salvaged for future renovation, if desired.

Still another object is to provide a modular cabinet structure whereby adjoining cabinets of the same height and depth dimensions can eliminate the need of the usually required two intermediate end panels.

In one aspect of the invention, the cabinet structure comprises a pair of vertically arranged rectangular end or side frames, constructed from elongated L-shaped members, which may be properly spaced and supported by a pair of horizontal rails, either L-shaped metal or solid wood. A pair of side or end panels having milled dado and rabbit cuts fit within the end frames, grooves or slots, and are adapted to interfit with one of the vertical L-shaped members of the end frames. Top and bottom panels are mounted inside of the supporting end frames, which are also further supported by their interfit with the dado grooves of the end or side panels. A front panel assembly having a hinged door and parts is adapted to interfit with the other parts to hold the cabinet in an assembled condition. A rear panel, if desired, may be United States Patent Patented June 2, 1970 mounted between the horizontal supporting rails and the end frames and be held in position by the top, bottom and side panels. The horizontal supporting rails are adapted for attachment to a wall or the like and the entire cabinet may be assembled or built-up piece by piece while being installed. When assembled, the interior of the cabinet is entirely void of corner posts and other protrusions when an L-shaped upper supporting rail is used within the upper corners of the end frames, and the front and side panels may be readily replaced without disassembly of the entire cabinet.

The foregoing and other objects, advantages and features of the invention will be apparent from the following description taken in conjunction with the accompanying drawings which illustrate an exemplary embodiment of the invention.

In the drawings:

FIG. 1 is a perspective view of the assembled cabinet mounted on a wall;

'FIG. 2 is a perspective view showing the supporting rails and one of the end frames of the knocked-down cabinet structure mounted on a wall;

FIG. 3 is an elevational view showing the inner face of one of the end or side panels;

FIG. 4 is a sectional view taken on the line 4-4 of FIG. 3;

FIG. 5 is a sectional view taken on the line 5-5 of FIG. 3;

FIG. 6 is an elevational view of the inner or rear side of the front panel assembly; and

FIG. 7 is a sectional view taken on the line 77 of FIG. 6.

Referring to the drawings, wherein similar reference characters designate like parts throughout the several views, and to FIG. 1 in particular, there is shown a cabinet 10 mounted on a wall 11 and comprising a front panel assembly designated generally by the numeral 12, side panels 13, a top panel 14, and a bottom panel 15. A door 16 is hingedly mounted on the panel assembly 12 by any desired hinge means, and in the embodiment illustrated, the front panel assembly includes a pair of end facing stiles 17 and 18 and a pair of cross facing members 19 and 20, if desired. The cabinet 10 is mounted on the Wall 11 by a pair of generally L-shaped supporting rails, only the upper rail 21 being shown in FIG. 1.

As hereinbefore indicated, the cabinet 10' is of the knocked-down type and is adapted for ready and simple assembly or build-up piece by piece on a wall or the like. Referring to 'FIG. 2, there is shown a pair of L-shaped supporting rails 21 and 22 having flanges 23, 24, 25 and 26, respectively, and attached to the wall 11 by screws or the like 28. The rails 21 and 22 are horizontally arranged on the wall 11 and support a rectangularly shaped end frame 29 (only one being shown in FIG. 2) at each end thereof. The end frames 29 comprise four interconnected elongated L-shaped bars 30, 31, 32 and 33 having flanges 34-35, 36-37, 38-39, and 40-41, respectively. While the bars 30-33 are illustrated as separate members joined together by spot Welds, rivets or the like 42, it is evident that they may be interconnected by any other means, or may be integrally formed.

In each of the end frames 29, the L-bar 30 is provided with a flat extension 43 at each end of flange 34 which underlies the rail 22 and is clamped by the rail upon tightening of the attaching screws 28'. To assure positive positioning and support of the end frames, screws or the like 44 and 46 may be utilized to interconnect the angle members 30 with the rails 21 and 22.

A rear panel 45, FIG. 2, may be inserted between the rails 21 and 22 with its ends overlying the flanges 34 of end frames 29 and extending to the flanges 35 so as to be clamped beneath portions of the side panels 13, as hereinafter described. The rear panel 45 may be further held in position during assembly of the cabinet by the sicrews 44 or the like passing through openings 44a and As best shown in FIGS. 3-5, the end of side panels 13 are solid rectangular members composed of wood or composition material of desired thickness with dado grooves 48 and 49 to accommodate the flanges 37 and 39 of the rectangular end frames. The thickness of the ungrooved interior surface is of a dimension suflicient to receive and provide added support to the horizontal frame members 29 and 32 and also engage the ends of the top panel 14 and the bottom panel 15, as hereinafter more fully explained. A rabbet 50 is also provided to accommodate the thickness of the back panel 45 at its ends. A slotted groove 51 cooperates for engagement with the flanges 39, as also hereinafter more fully described. A rabbet (47) of proper dimensions provides installation clearance of the front flange 41, and leaves an extended thickness of material at its front edge to be lockingly engaged and retained by the groove 52 in stiles 17 and 18 (FIGS. 1 and 7). The rectangular top and bottom panels 14 and (FIG. 1) are sized to fit between the end frames 29 with their ends contained within the flanges 37 and 39 and the horizontal dado channels 48 and 49 provided by the end panels 13. These panels 14 and 15 also overlie and assist in containing the rear panel 45, if used, in the assembled structure to further hold it in position, and the frames and panels are secured together at their outer ends by small nails or the like through holes 40a (FIG. 2) provided in the flange member 40 and near the ends of flanges 37 and 39 through holes 4012.

The front panel assembly 12 for the open end of the cabinet is best shown in FIGS. 1, 6 and 7 of the drawings and comprises the end stiles 17 and 18, cross members 19 and 20, a door 16, and hinges 51. The end stiles 17 and 18 and the cross members 19 and may be of wood or a composition material having a decorative plastictype of lamination bonded thereto, and while the end stiles and cross members are illustrated as being separate pieces, it is evident that they may comprise a single integral structure. Each of the end stiles of the front assembly 12 is provided with a grooved slot 52 and an adjacent rabbet 54, the grooves or slots 52 being adapted to receive the outer ends of the end panels '13 and the rabbets 54 to overlie the flanges 40 of the end frames 29. Positioned inwardly of the front panel members 17, 18, 19 and 20 are a pair of cross bars 55 and 56 which extend between the slots 52 at the top and bottom of the panel assembly. The bars 55 and 56 are attached to the members 17, 18, 19 and 20 by screws 57 and thus retain the front pieces in assembled position. As the stiles 17-18 interfit with end panels 13, the latter will also be secured in position.

The cross bars 55 and 56 are provided with rabbets 58 at the ends thereof which are adapted to fit over the flanges 36 and 38 of the end frames, and the bars are of such size as to lie along and abut the outer faces of the top and bottom panels 14 and 15 at the outer ends of the panels. Screws or like fastening means, not shown, passing through the panels 14 and 15 detachably secure the top and bottom panels to the cross bars 55 and 56, thereby detachably securing the front panel assembly 12 in position on the assembled cabinet, as well as the end panels 13, and providing a rigid cabinet structure having an interior which is completely clear of corner posts or other protrusions. The ends of the cross bars 55 and 56 lie in the spaces provided by the front frame clearance rabbet 47 of the end panels 13 while the flanges 36 and 38 of the end frames lie in the rabbets 58 of the cross bars to provide a flush abutment between the cross bars and the top and bottom panels. If desired, the interior surfaces of end panels 13 may be provided with two rows of openings 59 (FIG. 3) to accommodate hangers for a shelf, not shown, at different adjustable heights, or separate hanger strips, also not shown, may be attached to the surface between grooves 48 and 49 for this purpose.

The method of assembly the cabinet piece by piece in position on a wall will be apparent from the foregoing description. The lower supporting rail 22 is first loosely attached to the wall in a horizontal position by the screws 28. The outwardly extending portions 43 of the end frames 29 are then slipped under the supporting rail and clamped in position by tightening the screws 28. The upper supporting rail 21 of the desired predetermined length is next attached to the wall by screws 28 with its ends overlying and clamping the internal upper corners of the end frames 29. The rails and end frames may then be securely joined together by screws 44 passing through openings 44a (FIG. 2) provided at the ends of the rails. The rear panel 45 is now inserted between the end frames and will be held in position by the top and bottom panels 14 and 15 and rabbet 50 of panel 13. The top and bottom panels 14 and 15 and a shelf, if used, are then positioned between the end frames and are held in position by nails in holes 40a and 40b. The side panels 13 are then placed in position by slipping the groved or slotted ends over the flanges 35 and pressing the panels inwardly. The end panels now project through the openings of the end frames and, as above described, cooperate with flanges of the end frames to provide channels which receive the ends of the top and bottom panels and further hold them in proper position. Front panel assembly 12 is then placed in position with the outer ends of the side or end panels 13 received within the slotted grooves 52 of the front panel to thereby lock the end panels in position. The bars 55 and 56 are attached to the top and bottom panels 14 and 15 by screws 57 or like fastening means, as above described, to thereby hold the front panel assembly in place. Thus, the assembly of the cabinet structure is now complete with all parts securely locked in position.

It will be noted that the end panels are so interfitted with the end frames and the ends of the top and bottom panels that they complement each other and, hence, stabilize and reenforce the resulting cabinet structure.

It will be evident that the side or end panels 13 can be readily replaced, if damaged or to change the outer decor of the cabinet, by detaching the cross bars 55 and 56 from their connections with the top and bottom panels 14 and 15, removing the front panel assembly 12, and then removing one or both of the end panels. In like manner, one or more of the front panel facing members 17, 18, 19 and 20 can be readily replaced by merely removing the front panel assembly 12, as aforesaid, and detaching one or more of the facing members from the cross bars 55 and 56 by removing the screws 57. All of the other parts of the cabinet structure remain in place and are salvaged.

It will also be apparent that the length or width of the cabinet, i.e., the distance between the end panels 13, can be shortened within limits to fit within a smaller space by removing the door and its hinges and cutting down on the end stiles 17 and 18 to reduce the width thereof. The other longitudinally extending members such as the rails 21 and 22, the top and bottom panels 14 and 15, and the rear panel 45 would have to be correspondingly shortened to reduce the length thereof. It will further be apparent that the front panel assembly may be modified to provide a two door cabinet by merely adding two additional cross facing members 19 and 20 and a vertical center stile.

While the cabinet 10 has been illustrated and described as being of the wall type, it will be evident that the same structure and method of assembly are equally applicable to a floor cabinet. The front panel assembly 12 could be modified to provide one or more drawer openings and suitable guide tracks for the drawers would be mounted on the end panels. The cabinet could be mounted on the usual base member, and, if desired, the tops of the end frames 29 could be connected to a material saving wood frame as a substitute for panel 14 using the same procedure. The top of the cabinet could be covered by the usual counter top.

It will also be evident that other alterations, changes and modifications may be made in the cabinet structure, without departing from the spirit of the invention.

What is claimed is:

1. In a knock-down cabinet structure, the combination including a pair of rectangular vertical end frames each comprising four interconnected elongated L-shaped members having vertical flanges extending toward the openings of the end frames and horizontal flanges extending toward the opposite end frame, extended tabson one of said members of each frame for interconnecting said end frames to a supporting wall, a pair of end panels, each of said end panels having channels on one face thereof parallel to each of the edges thereof to interfit with said horizontal flanges to provide a main panel area on one side thereof to fit within the rectangular opening of said end frames, a grooved slot along one edge of said panels for engaging one of said vertical flanges on the end frames, top and bottom panels shaped to fit betweenthe horizontal flanges on said end frames, and a front panel assembly, said front panel assembly including a door means and means for attaching the assembling to the front of a pair of prior assembled parts whereby said vertical end frames and said top and bottom panels are concealed by said end panels and front panel assembly.

2. A knock-down cabinet structure as defined in claim 1 including a pair of spaced rail members, said extended tabs on said end frame members interfitting under said rail members adjacent the ends thereof for interconnecting said end frames to said rails.

3. A knocked-down cabinet structure as defined in claim 1 in which said part of the end panels which fits into the rectangular opening of said end frames cooperates with flanges on the end frame to provide channels for receiving the ends of said top and bottom panels to thereby secure the top and bottom panels in assembled position.

4. A knocked-down cabinet structure as defined in claim 3 wherein the inner side of said front panel assembly is provided with a grooved slot adjacent each end thereof, said slots providing channels for receiving the outer ends of said end panels to thereby secure the end panels in assembled position.

5. A knocked-down cabinet structure as defined in claim 4 wherein said front panel assembly is provided with a longitudinally extending rabbet adjacent each of said slots, said rabbets being positioned to overlie flanges on said end frames.

6. A knocked-down cabinet structure as defined in claim 5 in which said front panel assembly comprises at least two vertical facing members, at least two horizontal members, a pair of bars extending across the assembly at the top and bottom thereof, and fastening means for attaching each of said bars to said vertical facing members and one of said horizontal facing members.

7. A knocked-down cabinet structure as defined in claim 6 in which said front panel assembly includes a pair of bars extending between said slots at the top and bottom of the assembly, said bars being positioned to extend along the outer face of said top and bottom panels in abutting relation thereto, and fastening means for detachably connecting said bars to said top and bottom panels.

8. A knocked-down cabinet structure as defined in claim 2 in which a rear panel is positioned between said rails with its ends overlying flanges of said end frames and underlying portions of said slotted ends of said end panels.

9. The method of assembling a knocked-down cabinet of the type defined in claim 8, while in position on a wall which comprises the steps of vertically attaching the end extensions of a rectangular end frame clamped to a supporting wall, inserting a back panel between said end frames with the ends thereof overlying a flange of said end frames, inserting top and bottom panels between said end frames with flanges of the end frames overlying the ends of said panels, applying end panels having slotted grooves in an end wall and thickened portions adapted to fit within the openings of said end frames to said end frames by sliding said grooves over flanges on the end frames and pressing the panels inwardly, said thickened portions in cooperation with flanges on the end frames providing channels for receiving ends of said top and bottom panels, applying a grooved front panel assembly to the assembled structure with ends of 'said end panels extending into the grooves of said front panel assembly, said assembly being provided with a pair of cross bars adapted to abut said top and bottom panels, and attaching said cross bars to said top and bottom panels.

References Cited UNITED STATES PATENTS 1,481,560 1/1924 Ringer. 2,956,705 10/ 1960 Clingman. 2,966.385 12/1960 Murphy et al'. 3,222,116 12/1965 Levenberg 312245 3,301,622 1/1967 Dasovic et al 312-245 3,346,316 10/ 1967 Morioka et a1. 312-245 JAMES T. McCALL, Primary Examiner 

